Hardware product machining method

Abstract

The invention belongs to the technical field of metal machining, and particularly relates to a hardware product machining method which comprises the steps that S1, a first stamping head of a first stamping die is used for stamping a metal plate for the first time to form a plurality of first drainage grooves; s2, the metal plate is conveyed to a second station through the conveying device; s3, a plurality of first drainage grooves formed through stamping are correspondingly placed on a male die of a second stamping die to be accurately positioned; s4, a female die and a male die of a second stamping die are matched, so that the flat surfaces of the female die and the male die are pressed on the metal division bars around the first group of drainage grooves; s5, a second stamping head of the second stamping die conducts secondary stamping on the metal plate, and a second set of drainage grooves are formed; S6, the metal plate subjected to secondary stamping is pushed away from the male die through the conveying device, and the metal plate is synchronously pushed out of the machining area; the positioning device can achieve positioning in the continuous punching process when profiles with dense areas and easily damaged structural strength are punched.

Description

Technical Field

[0001] This invention belongs to the field of metal processing technology, and specifically relates to a method for processing hardware products. Background Technology

[0002] In metal processing, there is a type of continuous stamping, also known as progressive die stamping, which is a highly efficient and automated mass production process for metal parts. Its core equipment consists of a high-precision stamping press, an uncoiling, leveling, and feeding mechanism, a progressive die, and a take-up system. The core principle of this technology lies in using a progressive die that integrates all individual processes. On strips of metal, precise step-by-step feeding allows the strip to pass through different stations within the die for continuous processing. Finally, at the end of a stamping cycle, a blanking station separates the formed part from the strip, resulting in a complete component. The entire process begins with the uncoiling, leveling, and lubrication of the coil. Then, a servo feeding mechanism precisely feeds the strip into the die with strictly intermittent step-by-step feeding. During each stroke of the stamping press slide, the strip is progressively processed within the die, while waste generated during stamping is continuously discharged through a specially designed channel. Finally, the finished part is collected, while the remaining strip skeleton is either coiled or crushed. This technology, which integrates and makes continuous decentralized processes, greatly improves production efficiency and product consistency, and is one of the core technologies for the production of precision metal parts in modern manufacturing.

[0003] In the production of metal drain covers, the surface of the product is typically designed with multiple regularly arranged drainage grooves. If a one-time integral stamping process is used, the metal spacers between the drainage grooves will experience significant stretching and deformation due to insufficient structural strength under the continuous force of the die during stamping. Unlike conventional continuous stamping processes, metal materials generally maintain their structural integrity after stamping and are not prone to significant deformation, thus traditional positioning holes can still effectively achieve precise positioning. However, due to the dense arrangement of drainage grooves and the narrow spacing between them, metal drain covers experience a decrease in overall strength in certain areas due to repeated stress after multiple stamping cycles, leading to profile distortion or overall deformation. This deformation further causes the preset positioning hole positions to shift, thereby losing their positioning function.

[0004] Therefore, under current technological conditions, achieving high-precision positioning during continuous stamping of profiles with densely packed blanking areas and easily compromised structural strength remains a significant challenge, becoming a key technological bottleneck restricting the forming quality and production efficiency of such parts. Based on this, a hardware product processing method is proposed. Summary of the Invention

[0005] To address the aforementioned problems in the existing technology, the present invention provides a method for processing hardware products.

[0006] The objective of this invention can be achieved through the following technical solutions: The present invention provides a method for processing hardware products, comprising the following steps: S1: Initial stamping, at the first station, the metal sheet is stamped for the first time by the first stamping head of the first stamping die, forming the first set of drainage channels. The first set of drainage channels includes several first drainage channels arranged at regular intervals. S2: Transfer material, the metal sheet that has undergone the first stamping is conveyed to the second station through the conveying device; S3: Material positioning, the several first drainage grooves that have been stamped are placed on the punch of the second stamping die for precise positioning; S4: Material shaping, through the engagement of the die and punch of the second stamping die, wherein the contact part of the die and punch is a flat surface, and the flat surface is pressed against the metal spacer around the first set of drainage grooves; S5: Secondary stamping, at the second station, after clamping and positioning, the second stamping head of the second stamping die performs a second stamping on the metal sheet and forms a second set of drainage grooves. The second set of drainage grooves includes several second drainage grooves that are alternately arranged with several first drainage grooves. S6: Material ejection. The metal sheet, after the second stamping, is pushed away from the punch by the conveying device and simultaneously ejected from the processing area, completing the processing. Specifically, after the second stamping, the punch and die separate. The upward movement of the die simultaneously drives the vertical slide bar upward, causing the metal sheet fastened to the punch to rise vertically and separate from the punch. After the vertical slide bar drives the metal sheet upward, it is then driven to move horizontally by two rotating wheels.

[0007] As a further embodiment of the present invention, in step S2, the conveying device is arranged on both sides of the metal plate along the moving direction of the first station and the second station, and the conveying device clamps and drives the metal plate to move.

[0008] As a further aspect of the present invention, in step S3, the outer contour of the punch matches the inner contour of the first drainage groove, and the height of the punch is greater than the depth of the drainage groove.

[0009] As a further embodiment of the present invention, in step S3, the conveying device simultaneously provides a vertically downward force to the metal sheet while horizontally transferring the metal sheet, so that the bottom of the metal sheet slides against the punch until the first set of drainage grooves formed by the initial stamping moves to be aligned with the punch and then fastened to the punch.

[0010] As a further embodiment of the present invention, the conveying device includes a drive wheel assembly, which includes two rotating wheels arranged sequentially in a vertical direction. The two rotating wheels are rotatably mounted on a vertical slide rod, which is slidably mounted on the punch of the second stamping die. A spring is connected between the vertical slide rod and the punch to exert a pulling force on the vertical slide rod.

[0011] As a further aspect of the present invention, in step S4, during the stamping process at the second station, the pressing force applied to the metal spacer by the flat surface is 1.2-1.8 times the stamping force.

[0012] As a further embodiment of the present invention, in step S5, after the secondary stamping is completed, the second stamping head retracts first, and then the die rises and separates from the punch.

[0013] As a further embodiment of the present invention, in step S6, after the second stamping, the punch and die separate, and the upward separation action of the die simultaneously drives the vertical slide bar to move upward, so that the metal sheet fastened to the punch rises vertically and separates from the punch. After the vertical slide bar drives the metal sheet to move upward, it drives the metal sheet to move horizontally through two rotating wheels.

[0014] As a further embodiment of the present invention, magnets are provided on the die cavity of the second stamping die and the top of the vertical slide bar. The die separation action is achieved by the magnets attracting the vertical slide bar to rise and separating the metal sheet from the punch.

[0015] As a further aspect of the present invention, an elastic buffer device is provided on the die cavity of the second stamping die. When stamping the second set of drainage channels, the elastic buffer device is used to absorb part of the impact energy and reduce the vibration impact on the already positioned first set of drainage channels.

[0016] The beneficial effects of this invention are as follows: It integrates step-by-step stamping, positioning, and material shaping into a continuous automated process. The entire process begins with the initial stamping of a metal sheet at the first station, forming a first set of regularly arranged drainage channels. Subsequently, the metal sheet is transferred to the second station by conveying devices located on both sides of the metal sheet's movement direction. At this point, the vertical downward pressure applied by the conveying devices precisely engages the formed first set of drainage channels with the punch of the second stamping die, thereby utilizing the workpiece's own structure for positioning and effectively overcoming the positioning difficulties caused by the weakening and deformation of the material after the initial stamping. After positioning, the die descends, and its flat blanking surface first presses against the metal spacers around the drainage channels with a strong pressure greater than the stamping force, completing the correction and shaping of the deformed material and providing a stable foundation for subsequent stamping. Next, the second stamping head performs a second stamping on the shaped sheet, forming a second set of drainage channels alternating with the first set. After stamping, the die and sheet are first vertically lifted as a whole to achieve demolding, and finally, the finished sheet is horizontally pushed out of the processing area by the conveying device. This method, through the orderly connection of "positioning-shaping-stamping", ensures that continuous stamping can still be achieved even when the strength of the material structure changes dynamically, and finally produces floor drain products. Attached Figure Description

[0017] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0018] Figure 1 This is a flowchart of the steps of the present invention; Figure 2 This is a schematic diagram of the stamping equipment structure of the present invention; Figure 3 This is a schematic diagram of the metal floor drain structure of the present invention; Explanation of reference numerals in the attached drawings: 1. First stamping die; 2. Second stamping die; 21. Punch; 22. Die; 3. Conveying device; 4. Magnet; 5. Floor drain; 51. First drainage channel; 52. Second drainage channel; 53. Metal partition. Detailed Implementation

[0019] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided.

[0020] like Figures 1-3 As shown, a hardware product processing method of the present invention includes the following steps: S1: Initial stamping. At the first station, the metal sheet is stamped for the first time by the first stamping head of the first stamping die 1, forming the first set of drainage channels. The first set of drainage channels includes several first drainage channels 51 arranged at regular intervals. This stamping will remove some material, which will cause the strength of the metal spacers 53 between the drainage channels to decrease, and the sheet may warp slightly.

[0021] S2: Transfer material, the metal sheet that has undergone the first stamping is conveyed to the second station through the conveying device 3; S3: Material positioning, the several first drainage grooves 51 that have been stamped are respectively placed on the punch 21 of the second stamping die 2 for precise positioning; S4: Material shaping, through the engagement of the concave die 22 and the convex die 21 of the second stamping die 2, wherein the contact part of the concave die 22 and the convex die 21 is a flat surface, and the flat surface is pressed against the metal spacer 53 around the first set of drainage grooves; S5: Secondary stamping, at the second station, after clamping and positioning, the second stamping head of the second stamping die 2 performs a second stamping on the metal sheet and forms a second set of drainage grooves. The second set of drainage grooves includes a number of second drainage grooves 52 that are alternately arranged with a number of first drainage grooves 51. S6: Material ejection. The metal sheet that has undergone the second stamping is pushed away from the punch 21 by the conveying device 3, and the metal sheet is simultaneously ejected from the processing area to complete the processing.

[0022] For workpieces like metal floor drains with densely packed punched areas, the overall profile twists due to weakened strength after the initial punching, causing the preset positioning holes to shift and fail. By using the drainage groove itself formed by the first punching as the positioning reference for the second punching, and by pressing and shaping the deformed area before punching, the accuracy of the second punching is fundamentally guaranteed, effectively preventing processing defects caused by material deformation.

[0023] As a further aspect of the present invention, in step S2, the conveying device 3 is disposed on both sides of the metal sheet along the moving direction of the first and second workstations, and the conveying device 3 clamps and drives the metal sheet to move. In general continuous stamping equipment, the feeding device is located at the front and rear ends of the stamping moving direction, cooperating with the stamping action to drive the metal sheet to move on the stamping station. However, in structures like the metal floor drain 5 where the strength decreases after processing, simply setting the feeding device at the front and rear ends would cause the processed metal sheet to deform during movement. Therefore, it is necessary to place the conveying device 3 on both sides of the moving direction of the first and second workstations, directly clamping the metal sheet on both sides, which can prevent the deformation of the processed metal sheet caused by pushing or pulling actions.

[0024] As a further aspect of the present invention, in step S3, the outer contour of the punch 21 matches the inner contour of the first drainage groove 51, and the height of the punch 21 is greater than the depth of the drainage groove. This ensures that the sheet metal can be fully positioned. This method of positioning using its own machined features eliminates the reliance on traditional positioning holes, and can achieve adaptive and precise positioning even if the sheet metal as a whole has slight deformation.

[0025] As a further aspect of the present invention, in step S3, the conveying device 3 simultaneously applies a vertically downward force to the metal sheet while horizontally transferring it, causing the bottom of the metal sheet to slide against the upper part of the punch 21 until the first set of drainage grooves formed in the initial stamping moves to the alignment point of the punch 21 and engages with it. To achieve this effect, the metal sheet after the initial stamping has drainage grooves of varying lengths or sizes, rather than drainage grooves of equal length and width, or arc-shaped drainage grooves. Therefore, if the metal sheet after the initial stamping does not completely correspond to each corresponding position on the punch 21, it cannot be aligned and engaged. Alignment and engagement can only be achieved when the projection of the drainage groove coincides with the projection of the punch 21.

[0026] As a further embodiment of the present invention, the conveying device 3 includes a drive wheel assembly, which comprises two rotating wheels arranged sequentially in a vertical direction. The two rotating wheels are rotatably mounted on a vertical slide rod, which is slidably mounted on the punch 21 of the second stamping die 2. A spring is connected between the vertical slide rod and the punch 21 to exert a pulling force on the vertical slide rod. A position for clamping the metal sheet is formed between the two rotating wheels, and both rotating wheels are connected to a drive device. The drive device of the rotating wheels rotates and stops according to the stamping action steps. When it is necessary to transfer the metal sheet, the rotating wheel rotates; when the drainage groove of the metal sheet is engaged with the punch 21, the rotating wheel stops. This action is electrically connected to the drive device and automatically controlled by a control device.

[0027] A spring connected to the punch 21 on the vertical slide bar creates a pulling force on the slide bar. When the metal sheet is moved, it is pulled to slide against the top of the punch 21. After the drainage groove aligns with the punch 21, the pulling force causes the metal sheet to snap onto the punch 21. After the second stamping, when the die 22 separates from the punch 21, the vertical slide bar and the die 22 form a brief connection. The upward movement of the die 22 causes the vertical slide bar to rise, which in turn causes the two rotating wheels to move the metal sheet upward synchronously. The drainage groove of the metal sheet then rises and separates from the punch 21, and under the rotation of the rotating wheels, it moves horizontally to the next workstation. Since the metal sheet has a continuous structure, this movement pulls the parts that have completed the initial stamping forward, while the parts that have completed the second stamping move to the next workstation for the next process.

[0028] As a further aspect of the present invention, in step S4, during the stamping process at the second station, the clamping force applied to the metal spacer 53 by the flat surface is 1.2-1.8 times the stamping force. This ensures that the formed metal spacer 53 will not be displaced or deformed due to force when stamping the second set of drainage channels.

[0029] As a further embodiment of the present invention, in step S5, after the secondary stamping is completed, the second stamping head is first retracted by the telescopic drive mechanism on the die 22, and then the die 22 is raised and separated from the punch 21.

[0030] As a further aspect of the present invention, magnets 4 are provided on the die 22 of the second stamping die 2 and on the top of the vertical slide bar. The separation action of the die 22 is achieved by the magnets 4 magnetically attracting the vertical slide bar to rise and separating the metal sheet from the punch 21. The vertical slide bar is provided with a limiting structure. When the die 22 descends and fits against the punch 21, the magnets 4 on the die 22 and the magnets 4 on the vertical slide bar are magnetically attracted and fitted together. When the die 22 rises, it drives the vertical slide bar to rise. When the vertical slide bar is driven to the position of the limiting structure, the die 22 continues to rise, which will cause the two magnets 4 to separate. Then, the vertical slide bar will return to its original position under the tension of the spring. When the vertical slide bar rises, the roller will rotate to move the metal sheet, so that the projection of the drainage groove and the punch 21 no longer coincides. Therefore, after the vertical slide bar returns to its original position, the drainage groove will not re-attach to the punch 21.

[0031] As a further embodiment of the present invention, an elastic buffer device is provided on the die 22 of the second stamping die 2. When stamping the second set of drainage grooves, the elastic buffer device is used to absorb part of the impact energy and reduce the vibration impact on the already positioned first set of drainage grooves. Specifically, the buffer device can be a spring or a spring rod.

[0032] Working Principle: The process integrates step-by-step stamping, positioning, and material shaping into a continuous automated flow. The entire process begins with the initial stamping of the metal sheet at the first station, forming the first set of regularly arranged drainage channels 51. Subsequently, the metal sheet is transferred to the second station by conveyor devices 3 located on both sides of the sheet's movement direction. At this point, the vertical downward pressure applied by the conveyor devices 3 precisely engages the formed first set of drainage channels with the punch 21 of the second stamping die 2, thus achieving precise positioning using the workpiece's own structure. This effectively overcomes the positioning difficulties caused by the weakened material strength and easy deformation after the initial stamping. After positioning, the die 22 descends, and its flat blanking surface presses against the metal spacers 53 around the drainage channels with a strong pressure greater than the stamping force, completing the correction and shaping of the deformed material and providing a stable foundation for subsequent stamping. Immediately afterwards, the second stamping head performs a second stamping on the shaped sheet, forming the second set of drainage channels, alternating with the first set. After the first drainage channel 51 and the second drainage channel 52 are stamped, they are punched out from the metal sheet to form the floor drain 5 product. After stamping, the die 22 is first vertically lifted along with the sheet to achieve demolding, and finally the finished sheet is horizontally pushed out of the processing area by the conveying device 3. This method, through the orderly connection of "positioning-shaping-stamping", ensures that continuous stamping can still be achieved even when the strength of the material structure changes dynamically, and finally produces the floor drain 5 product.

[0033] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method of processing hardware, characterized by: The method comprises the following steps: S1: primary stamping, at a first station, a first stamping head of a first stamping die is used to stamp a metal plate for the first time to form a first group of drainage channels, the first group of drainage channels comprising a plurality of first drainage channels arranged at regular intervals; S2: material transfer, a conveying device is used to transfer the metal plate after the first stamping to a second station; S3: material positioning, the plurality of first drainage channels formed after the stamping are respectively placed on a male die of a second stamping die for accurate positioning; S4: material shaping, a female die of the second stamping die is used in cooperation with the male die, wherein a flat surface of the female die and the male die is used to press the metal partition strip around the first group of drainage channels; S5: secondary stamping, after the pressing and positioning, a second stamping head of the second stamping die is used to stamp the metal plate for the second time to form a second group of drainage channels, the second group of drainage channels comprising a plurality of second drainage channels arranged alternately with the plurality of first drainage channels; S6: material pushing, the conveying device is used to push the metal plate away from the male die after the second stamping, and the metal plate is pushed out of the processing area at the same time, and the processing is completed.

2. The method of claim 1, wherein: In the step S2, the conveying device is arranged on both sides of the metal plate in the moving direction of the first station and the second station, and the conveying device clamps and drives the metal plate to move.

3. The method of claim 1, wherein: In the step S3, the outer profile of the male die matches the inner profile of the first drainage channel, and the height of the male die is higher than the depth of the drainage channel.

4. The method of claim 2, wherein: In the step S3, the conveying device provides a vertical downward force to the metal plate when horizontally transferring the metal plate, so that the bottom of the metal plate slides and fits above the male die until the first group of drainage channels formed after the primary stamping are moved to align with the male die and are buckled on the male die.

5. A method of processing a hardware article according to claim 4, wherein: The conveying device comprises a driving wheel set, the driving wheel set comprises two rotating wheels arranged in sequence in the vertical direction, the two rotating wheels are rotationally arranged on a vertical slide rod, the vertical slide rod is slidingly arranged on the male die of the second stamping die, and a spring is connected between the vertical slide rod and the male die to form a pulling force on the vertical slide rod.

6. The method of claim 1, wherein: In the step S4, during the stamping process at the second station, the pressing force of the flat surface on the metal partition strip is 1.2-1.8 times the stamping force.

7. The method of claim 1, wherein: In the step S5, after the secondary stamping is completed, the second stamping head is retracted first, and then the female die is raised and separated from the male die.

8. The method of claim 5, wherein: In the step S6, after the secondary stamping, the male die and the female die are separated, the female die is raised and separated synchronously, the metal plate buckled on the male die is vertically raised and separated from the male die, and the vertical slide rod drives the metal plate to move upward after the vertical slide rod drives the metal plate to move horizontally.

9. The method of claim 8, wherein: A magnet is arranged on the female die of the second stamping die and the top of the vertical slide rod, and the female die separation action is realized by the magnet attracting the vertical slide rod to rise and separating the metal plate from the male die.

10. The method of claim 1, wherein: An elastic buffer device is arranged on the female die of the second stamping die, and the elastic buffer device is used to absorb part of the impact energy when stamping the second group of drainage channels, thereby reducing the vibration influence on the first group of drainage channels which have been positioned.

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